Door Panels – Removal and Installation

Overview

This procedure explains how to remove and install the door panels on a Porsche 944 with a 16v engine. Removing the door panels is necessary for accessing interior components like window regulators, door locks, or speakers. Proper handling prevents damage to the panels and ensures a secure reinstallation. This guide is specific to the late-model door panel design used in the 944 (1989–1991).

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Tools Required

• Phillips head screwdriver (#2)
• Flathead screwdriver (small)
• 10mm (3/8 inch) socket and ratchet
• Door panel removal tool (or plastic pry tool)
• Torque wrench (covering 5-10 Nm / 4-7 ft-lbs)

Parts Required

• Door panel clips (if damaged, 999 591 327 03)
• Door panel screws (if lost, 999 919 071 02)

Step-by-Step Procedure

Step 1: Prepare the Vehicle

1. Park the vehicle on a flat surface in a well-lit area.
2. Ensure the ignition is off and the windows are fully lowered to avoid stress on the door panel.
3. Disconnect the negative battery terminal using a 10mm (3/8 inch) socket to prevent electrical issues.

Step 2: Remove Door Panel Components

4. Remove the door handle surround by gently prying it with a flathead screwdriver and pulling it away from the panel.
5. Remove the two Phillips screws inside the door handle recess, securing the inner handle assembly (999 919 071 02).
6. Pry off the armrest cover using a door panel removal tool and remove the two Phillips screws underneath.
7. Remove the speaker grille (if equipped) by prying gently with a flathead screwdriver, then remove the Phillips screw behind it.

Step 3: Remove the Door Panel

8. Insert a door panel removal tool between the door panel and the door frame, starting at the bottom edge, to release the plastic clips (999 591 327 03).
9. Work around the panel’s perimeter, gently popping each clip free, and avoid pulling too hard to prevent breaking the clips.
10. Lift the door panel upward to disengage the top lip from the window channel, then pull it away from the door.
11. Disconnect any electrical connectors (e.g., for power windows or mirrors) by pressing the release tabs and pulling gently.

Step 4: Inspect and Prepare for Installation

12. Inspect the door panel for damaged clips or screws, replacing any broken clips (999 591 327 03) or screws (999 919 071 02).
13. Check the door’s vapor barrier (plastic sheet) for tears, ensuring it’s intact to prevent water intrusion.
14. Clean the door panel and frame with a mild cleaner to remove dirt or debris before reinstallation.

Step 5: Install the Door Panel

15. Reconnect any electrical connectors to the door panel, ensuring they click securely into place.
16. Align the door panel’s top lip with the window channel and lower it onto the door frame.
17. Press firmly around the panel’s perimeter to snap the clips (999 591 327 03) back into place, starting at the top and working downward.
18. Reinstall the Phillips screw behind the speaker grille (if equipped) and snap the grille back into place.
19. Secure the armrest with the two Phillips screws and snap the cover back on.
20. Reinstall the two Phillips screws in the door handle recess and snap the door handle surround into place.

Step 6: Finalize and Test

21. Reconnect the negative battery terminal and tighten to 10 Nm (7 ft-lbs) using a 10mm (3/8 inch) socket.
22. Turn on the ignition and test power windows, mirrors, or speakers (if equipped) to ensure proper function.
23. Check the door panel for secure attachment by gently tugging at the edges to confirm no loose clips.
24. Drive the vehicle for 5 miles (8 km) to verify the panel remains secure under vibration.

Post Procedure Checklist

• Confirm the door panel is securely attached with no loose clips or rattles.
• Verify all electrical components (e.g., power windows, mirrors) function correctly.
• Check that all screws are tightened to 5 Nm (4 ft-lbs) and the battery terminal to 10 Nm (7 ft-lbs).
• Ensure the door handle surround and armrest cover are flush and secure.
• Inspect the vapor barrier for proper sealing to prevent water intrusion.

Sources

• Clark’s Garage
• Pelican Parts
• Porsche 944 Workshop Manual, Volume 1
• Youtube